Long-Chain Chemicals (LCPFCs) Used in Carpets

[Pages:1]Long-Chain Perfluorinated

Chemicals (LCPFCs) Used in

Carpets

Contract # EP-W-08-010

July 27, 2012

-- Does not contain TSCA CBI --

Prepared for: Economic and Policy Analysis Branch Economics, Exposure and Technology Division Office of Pollution, Prevention, and Toxics

U.S. Environmental Protection Agency 1200 Pennsylvania Avenue Washington, DC 20460

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Long-Chain Perfluorinated Chemicals (LCPFCs) in Carpets

Contract # EP-W-08-010

Long-Chain Perfluorinated Chemicals Used in Carpets Table of Contents List of Exhibits...................................................................................................................................... v Contributors......................................................................................................................................... vi Executive Summary ........................................................................................................................... vii 1. Introduction.............................................................................................................................1-1 2. Carpet Manufacturing............................................................................................................2-1

2.1 Introduction ....................................................................................................................2-1 2.2 Manufacturers Using PFCs in Carpet Products ..............................................................2-1 2.3 Manufacturers of Remaining Carpet Products with Long-Chain PFCs .........................2-1

2.3.1 Advanced Polymer, Inc., Carlstadt, NJ.............................................................2-1 2.4 Carpet Manufacturing Process........................................................................................2-2 2.5 Carpet Treatment ............................................................................................................2-2 3. Industry Overview ..................................................................................................................3-4 3.1 Sector Definition ............................................................................................................3-4

3.1.1 Primary Manufacturing: Chemical Manufacturing...........................................3-4 3.1.2 Secondary Manufacturing: Carpet Manufacturing and Treatment ...................3-4 3.2 Economic Activity..........................................................................................................3-5 3.3 NAICS Sectors Potentially Using PFCs in Carpets........................................................3-6 3.4 Exports, Imports, and Domestic Consumption...............................................................3-7 3.4.1 U.S. International Trade Commission Data on Imports, 2000 ? 2010 .............3-9 4. Role of PFCs in Carpet Manufacturing................................................................................4-1 4.1 Fluorotelomers in Carpets ..............................................................................................4-2 4.2 PFAS in Carpets .............................................................................................................4-5 5. Availability of Alternatives ....................................................................................................5-1 5.1 Clariant ...........................................................................................................................5-1 5.2 DuPont............................................................................................................................5-1

Front Matter pg. iii

Long-Chain Perfluorinated Chemicals (LCPFCs) in Carpets

Contract # EP-W-08-010

5.3 AGC Chemicals Americas (Asahi).................................................................................5-3 5.4 Daikin Industries ............................................................................................................5-3 5.5 Solvay Solexis ................................................................................................................5-4 5.6 BASF ..............................................................................................................................5-4 5.7 Advanced Polymer Inc. ..................................................................................................5-5 5.8 3M...................................................................................................................................5-5 5.9 Other Alternatives ..........................................................................................................5-5 5.10 Conclusions ....................................................................................................................5-7 6. References................................................................................................................................6-1

Front Matter pg. iv

Long-Chain Perfluorinated Chemicals (LCPFCs) in Carpets

Contract # EP-W-08-010

List of Exhibits

Exhibit 1-1: Normalized Distribution of Fluorotelomers in Use Sectors Based on Total Reported Production Volume..................................................... Error! Bookmark not defined.1-2

Exhibit 3-1: Textile Product Mill Sectors: Economic Activity, 2007 ................................................3-5 Exhibit 3-2: Carpet and Rug Mills: Economic Activity, Historical Data ...........................................3-5 Exhibit 3-3: Carpet and Rug Mill Product Lines: Economic Activity, 2007......................................3-6 Exhibit 3-4: Carpet and Rug Mills: Imports, Exports, and Implied Domestic Consumption, 2007...3-8 Exhibit 3-5: Carpet and Rug Mills: Imports, Exports, Value of Shipments ($1,000), 2007 ..............3-9 Exhibit 3-6: Carpet and Impregnated Fabrics: U.S. Imports, ($1,000,000)......................................3-11 Exhibit 3-7: Carpet Imports, ($1,000,000) .......................................................................................3-12 Exhibit 3-8: Impregnated Fabrics Imports, ($1,000,000) .................................................................3-12 Exhibit 4-1: PFCs in Carpet ................................................................................................................4-2 Exhibit 4-2: Fluorotelomers and Chemicals Containing Fluorotelomers Used in Polyurethane Resin4-3 Exhibit 4-3: Fluorotelomers Used in Polyurethane Resin with 2006 IUR Production Data ..............4-4 Exhibit 4-4: PFAS Compounds with 2002, or 2006 IUR Production Volume...................................4-5 Exhibit 5-1: UNIDYNE Multi-SeriesTM Water and Oil Repellent Products.......................................5-4

Front Matter pg. v

Long-Chain Perfluorinated Chemicals (LCPFCs) in Carpets

Contract # EP-W-08-010

Contributors

The EPA analyst responsible for this report is Timothy Lehman of the Economic and Policy Analysis Branch; Economics, Exposure and Technology Division; Office of Pollution Prevention and Toxics. Analytical and draft preparation support was provided by Abt Associates, Inc. under EPA Contract No. EP-W-08-010.

Front Matter pg. vi

Long-Chain Perfluorinated Chemicals (LCPFCs) in Carpets

Contract # EP-W-08-010

Executive Summary

Perfluorinated chemicals (PFCs) are substances with special properties that have a variety of industrial applications. PFCs are used in carpets to impart stain, soil, and grease repellant properties (U.S. EPA 2009c; KEMI 2006). During the manufacturing process, PFCs are utilized in the impregnation of carpets or as a chemical finish which endows fabrics with those characteristics. Long-chain perfluorinated chemicals (LCPFCs) are found world-wide in the environment, wildlife, and humans. They are bioaccumulative in wildlife and humans, and are persistent in the environment (Danish Ministry of the Environment 2008).

There are four typical scenarios for chemical application that could lead to the presence of LCPFCs in carpet products. First, LCPFCs could be applied to carpet at a carpet and rug mill during the manufacturing process. Secondly, LCPFCs could be applied to carpet after the manufacturing process at a separate finishing facility. Thirdly, treatment products containing LCPFCs could be applied to carpets by final consumers in the post manufacturing stage. In the described scenarios, LCPFCs could be domestically produced or imported. In addition, domestically produced carpets could be made using imported fabrics that had been treated with LCPFCs. Finally, carpet containing LCPFCs could be imported into the United States as a final product.

The Agency believes that the LCPFC chemical substances included in the proposed rule are no longer being manufactured, processed, or imported for use as part of carpet or for treating carpet (e.g., for use in the carpet aftercare market) in the United States. Partly as a result of the 2010/15 PFOA Stewardship Program, U.S. manufacturers have stopped producing LCPFC-based products used for carpet treatment. Major manufacturers have developed alternative products that are based on short-chain PFCs. However, a few companies continue to sell previously manufactured products that use LCPFCs. It is expected that no LCPFC-based products will be available for sale in the U.S. once the existing inventory is sold out.

In addition to the phase-out of long-chain PFCs in carpet products by domestic manufacturers, EPA believes that imported carpet products do not contain LCPFCs. Only 16 percent of domestically consumed carpets and rugs are imported, while 84 percent of the product is manufactured in the U.S.

Long-chain PFCs may also be imported into the U.S. from countries like China and applied to carpets domestically. The imports data obtained from ITC suggest that no long-chain PFCs for use in carpet treatment are currently imported into the U.S.

Because chemical treatments for carpets are not only applied during the manufacturing process but can also be applied to carpets by the consumers in the post manufacturing stage, exposure to carpet treatment chemicals may occur both during and after the manufacturing process.

This market profile is developed to support the Significant New Use Rule (SNUR) being proposed by EPA for long-chain PFCs used in carpets.

Front Matter pg. vii

Long-Chain Perfluorinated Chemicals (LCPFCs) in Carpets

Contract # EP-W-08-010

1. Introduction

Perfluorinated chemicals (PFCs) are substances with special properties that have a variety of industrial applications. PFCs are used widely in the textile industry because of their thermo-stability, ability to adapt to a variety of surface characteristics, high chemical stability, and other characteristics (Armeduri and Bouterin 2004). PFCs are used in carpets to impart stain, soil, and grease repellant properties (U.S. EPA 2009c; KEMI 2006). During the manufacturing process, PFCs are utilized in the impregnation of carpets or as a chemical finish which endows fabrics with those characteristics.

Long-chain perfluorinated chemicals (LCPFCs) are found world-wide in the environment, wildlife, and humans. They are bioaccumulative in wildlife and humans, and are persistent in the environment (Danish Ministry of the Environment 2008). To date, significant adverse effects have not been found in the general human population1; however, LCPFCs have been linked to a number of health effects, including thyroid disease and reproductive function (Knox, et al., 2011; Melzer, et al., 2010).

Although three broad types of PFCs are used in textiles: fluorotelomers, fluoropolymers, and perfluoroalkyl sulfate (PFAS), we found no evidence of fluoropolymers used in carpet treatment products.

This market profile is developed to support regulatory activities that would limit or eliminate the use of long-chain PFCs (LCPFCs) in carpets. This market profile in support for the Significant New Use Rule (SNUR) being proposed by EPA for LCPFCs used in carpets is structured in the following way:

Section 2 identifies individual manufacturers of PFCs and provides a description of the carpet manufacturing process.

Section 3 provides an overview of the carpet manufacturing sector and its economic activity.

Section 4 defines the role of PFCs in the carpet industry.

Section 5 lists available alternatives to LCPFC-based carpet treatment products.

1 Based on review of a number of studies examining health effects of LCPFCs. Introduction pg. 1-1

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